System for inflating packing material

ABSTRACT

A dunnage bag includes a sealed, flexible bag, and a rigid valve assembly connected in fluid communication to the flexible bag. The valve assembly has a rigid collar which mounts in an opening in a wall of a container to receive an exit end of a fill nozzle of an inflating system which supplies pressurized gas for inflating the flexible bag.

CROSS REFERENCE TO RELATED APPLICATION

Under 35 USC §120 this is a divisional application of U.S. Ser. No.09/059,791, filed Apr. 13, 1998 now U.S. Pat. No. 6,253,919.

BACKGROUND OF THE INVENTION

This invention relates to inflatable packing material, in particulardunnage air bags.

Dunnage air bags are typically used to fill void regions in containerscarrying articles for shipment. When the bag is inflated, the article iswedged between the bag and the walls of the container or betweenportions of the bag. Thus the article is prevented from moving around inthe container while being shipped. The bag is usually made from apuncture resistant material to ensure that the bag remains inflatedduring the shipment of the article.

SUMMARY OF THE INVENTION

In general, according to one aspect of the invention, a dunnage bagincludes a sealed, flexible bag, and a rigid valve assembly connected influid communication to the flexible bag. The valve assembly has a rigidcollar which mounts in an opening in a wall of a container to receive anexit end of a fill nozzle of an inflating system which suppliespressurized gas for inflating the flexible bag.

Embodiments of this aspect of the invention may include one or more ofthe following features. The flexible bag includes a pleat for relievingstrain on the flexible bag near the valve assembly when the dunnage bagis in use in the container. The flexible bag has a quilted construction.The collar includes a first rim located at an entrance end of the collarand a second rim spaced apart from the first rim. The first rim has asmaller diameter than the second rim and a larger diameter than aportion of the collar located between the first rim and the second rim.The first rim is tapered to sealably engage the exit end of the fillnozzle. The rigid collar is configured so that the entrance end of thecollar is flush with an outer surface of the wall of the container whenthe rigid collar is mounted in the wall. Alternatively, the rigid collaris configured so that the entrance end of the collar is recessed from anouter surface of the wall of the container when the rigid collar ismounted in the wall.

In other embodiments of this aspect, the rigid collar includes a thirdrim spaced apart from the second rim, where the third rim extendsinwardly into a bore defined by the rigid collar. The rigid collar isconfigured so that the entrance end of the collar protrudes from anouter surface of the wall of the container when the rigid collar ismounted in the wall.

In another aspect of the invention, a dunnage bag includes a sealed,flexible bag, and a flexible valve assembly connected in fluidcommunication to the flexible bag at a first end of the valve assembly.The valve assembly has a rigid collar at another end of the valveassembly which mounts in an opening in a wall of a container to receivea fill nozzle of an inflating system which supplies pressured gas forinflating the flexible bag.

Embodiments of this aspect of the invention may include any of thefeatures discussed above, as well as the following additional features.The flexible bag includes two opposed sides and the first end of thevalve assembly is connected to the flexible bag near a center region ofone of the two opposed sides. Alternatively, the flexible bag includestwo opposed sides and the first end of the valve assembly is connectedto the flexible bag near an edge of the flexible bag.

In another aspect of the invention, a dunnage bag includes a sealed,flexible bag, and a valve assembly connected in fluid communication tothe flexible bag. The valve assembly has a rigid collar which mounts inan opening in a wall of a container to receive a fill nozzle of aninflating system which supplies pressurized gas for inflating theflexible bag. The collar has a first rim located at an entrance end ofthe collar and a second rim positioned next to the first rim. The firstrim has a smaller diameter than the second rim and a larger diameterthan a portion of the collar located between the first rim and thesecond rim.

Embodiments of this aspect of the invention may include any of thefeatures discussed above.

In still another aspect of the invention, a dunnage bag includes asealed, flexible bag, and a flexible valve assembly connected in fluidcommunication to the flexible bag at an end of the valve assembly. Thevalve assembly has an outer portion with an adhesive for attaching theouter portion to a wall of a container to receive a fill nozzle of aninflating system which supplies pressured gas for inflating the flexiblebag.

Embodiments of this aspect of the invention may also include any of thefeatures discussed above.

In another aspect of the invention, a dunnage bag includes a sealed,flexible bag having multiple protrusions extending outwardly from asurface of the flexible bag, and a valve assembly connected in fluidcommunication to the flexible bag. The valve assembly is configured toreceive an exit end of a fill nozzle of an inflating system whichsupplies pressurized gas for inflating the flexible bag.

In yet another aspect of the invention, a dunnage bag includes a sealed,flexible bag which has a first portion with a substantially smooth outersurface, and a second portion with a quilted construction, and a valveassembly connected in fluid communication to the flexible bag. The valveassembly is configured to receive an exit end of a fill nozzle of aninflating system which supplies pressurized gas for inflating theflexible bag.

In still another aspect of the invention, a dunnage bag includes acontainer, a sealed, flexible bag disposed within and attached to thecontainer, and a valve assembly connected in fluid communication to theflexible bag. The valve assembly is configured to receive an exit end ofa fill nozzle of an inflating system which supplies pressurized gas forinflating the flexible bag.

In another aspect of the invention, a packaging system includes aninflating system which provides pressurized gas for inflating a dunnagebag disposed within a rigid container holding an article; a tapingsystem which applies tape on the container to seal the container; and aconveying system which transports the container to and from theinflating system and the taping system. The taping system is attached tothe conveying system.

Embodiments of this aspect of the invention may include one or more ofthe following features. The packaging system includes a controller whichcauses the taping system and inflating system to perform automatically.The inflating system includes a pressure regulation system whichcontrols the inflation of the bag. The pressure regulation system iscontrolled by a feedback controller such that the bag is inflated instages. The feedback controller monitors the pressure within the bag andthe flow rate of air to the bag. The packaging system includes a swelldetector which detects deflection of a wall of the container duringinflation of the dunnage bag. The inflating system and taping system areactivated manually. The inflating system includes a fill nozzle having apliable material at an exit end of the nozzle which sealably engageswith a collar of a valve assembly connected in fluid communication withthe bag. The packaging system includes a sound generator which producesa sound such that the amplitude and pitch of the sound corresponds tothe flow rate of air through the sound generator.

In still another embodiment of the invention, an inflating systemincludes a fill nozzle which engages with an entrance end of a valveassembly of a dunnage bag for supplying pressurized gas to the bag forinflating the bag, and a pressure regulation system which controls theinflation of the bag.

Embodiments of this aspect of the invention may include one or more ofthe following features. The pressure regulation system is controlled bya feedback controller such that the bag is inflated in stages. Thefeedback controller monitors the pressure within the bag and the flowrate of air to the bag. The fill nozzle includes a pliable material atan exit end of the nozzle which sealably engages with a collar of avalve assembly connected in fluid communication with the bag. Theinflating system includes a swell detector which detects deflection of awall of a container during inflation of the dunnage bag disposed withinthe container.

In yet another aspect of the invention, an inflating system includes afill nozzle which engages with an entrance end of a valve assembly of adunnage bag for supplying pressurized gas to the bag for inflating thebag, and a swell detector which detects deflection of a wall of acontainer during inflation of a bag within the container. In certainembodiments of this aspect, the swell detector is a linear transducer.

In another aspect of the invention, a method for packaging an articleincludes placing a dunnage bag inside a rigid container along with thearticle; mounting a valve assembly of the dunnage bag in an opening in awall of the container; and, by means of an automated system, supplyingpressurized gas to the valve assembly to inflate the bag; and sealingthe container with tape. The dunnage bag includes a sealed, flexiblebag, and the valve assembly connected in fluid communication to the bag.

In some embodiments of this aspect of the invention, the step ofsupplying is performed before the step of sealing. And in otherembodiments, the step of supplying is performed after the step ofsealing.

Among other advantages, the dunnage bag facilitates packaging articlesfor shipment quickly. The bag requires less material to assemble thanthe prior art. In at least one embodiment, the valve assembly does notprotrude outside the container and thus can not be snagged and rippedout of the container. The inflation of the bag can be readily automated.The packaging system is able to inflate the bag and seal the containersimultaneously without requiring manual intervention from an operator.

Other features and advantages of the invention will become apparent fromthe following detailed description and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of a dunnage bag incorporating a rigid valveassembly;

FIG. 2A is a front view of the rigid valve assembly of the dunnage bagof FIG. 1;

FIG. 2B is a side cross-sectional view along line 2B—2B of FIG. 2A;

FIG. 2C is a side cross-sectional view along line 2C—2C of FIG. 2A;

FIG. 2D is a side cross-sectional view of the rigid valve assembly ofFIG. 2A mounted in an opening of a wall of a container;

FIG. 3 is a perspective view of the dunnage bag of FIG. 1 in use in acontainer;

FIG. 4A is an illustration of a packaging system for inflating thedunnage bag of FIG. 1;

FIG. 4B is a side cross-sectional view of the rigid valve assembly ofthe dunnage bag of FIG. 1 during inflation of the bag;

FIG. 5 is a block diagram of an inflating system for the packagingsystem of FIG. 4A;

FIG. 6 is a partial top view of an alternative embodiment of a packagingsystem incorporating a box swell detector;

FIG. 7A is an illustration of alternative embodiment of a dunnage bagincorporating a flexible valve assembly;

FIG. 7B is a close-up view of the flexible valve assembly of the dunnagebag of FIG. 6A;

FIG. 7C is an illustration of another alternative embodiment of adunnage bag incorporating a flexible valve assembly;

FIG. 8 is an illustration of yet another alternative embodiment of adunnage bag incorporating a flexible valve assembly;

FIG. 9 is an illustration of an alternative embodiment of a rigid valveassembly;

FIG. 10 is an illustration of an alternative embodiment of a dunnage bagof quilted construction;

FIG. 11 is an illustration of an alternative embodiment of a compositedunnage bag;

FIG. 12A is an illustration of another alternative embodiment of adunnage bag with protrusions; and

FIG. 12B is an illustration of the dunnage bag of FIG. 12A in use in acontainer.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, a dunnage bag 10 includes a flexible bag 12 with apleat 14, and a rigid valve assembly 16 mounted in the pleat. Twoopposed sides 17, 18 of flexible bag 12 are sealed along three edges 20,22, 24, and pleat 14 is sealed along a pair of edges 26, 28 with opposedsides 17, 18, respectively. Pleat 14 is a folded piece of material thatunfolds when dunnage bag 10 is inflated to provide increased volumeexpansion of the bag. Side 18 also includes a fold (not shown) thatunfolds to provide further volume expansion of bag 10 when the bag isinflated.

Flexible bag 12 is typically made from a pliable, sealable material, forexample linear, low density polyethylene. Flexible bag 12 can also bemade from other materials including medium or high density polyethylene.Flexible bag 12 can also include a polyester or nylon outer layer, forstrength and abrasion resistance, and a low-density polyethylene innerbag for heat sealability.

Referring to FIGS. 2A-2C, rigid valve assembly 16 includes a housing 32,and a circular diaphragm 34 secured within housing 32 by a retainer post36. Housing 32 defines a bore 38 which extends from an entrance opening40 of housing 32 to an enlarged bore 42 located at the other end of thehousing. A circular ledge 44 extends inwardly into enlarged bore 42 anddefines an exit opening 46. Retainer post 36 includes two ends 48, 50engaged with ledge 44 of housing 32 such that two outer portions 52, 54of diaphragm 34 are held against a surface 56 of housing 32 to holddiaphragm 34 within housing 32. Diaphragm 34 includes two side portions58, 60 located on either side of retainer post 36. Portions 58, 60 ofdiaphragm 34 mate up against surface 56 of housing 32 to form a seal,when flexible bag 12 is inflated to about 2 to 3 psi. Housing 32includes an outwardly extending rim 62 which has a tapered surface 68,and an outwardly extending shoulder 70 spaced from rim 62. Shoulder 70is larger in diameter than rim 62. A base portion 76 of housing 32includes another surface 78 which is adhered to flexible bag 12.

In the embodiment of the valve assembly illustrated in FIGS. 2A-2C, bore38 has a diameter, D₁, of about 0.3 inch. The diameter, D₂, of enlargedbore 38 is about 0.6 inch, and exit opening 46 defined by circular ledge44 has a diameter, D₃, of about 0.55 inch. Rim 62 has an outer diameter,D₄, of about 0.5 inch, and shoulder 70 has an outer diameter D₅ of about0.7 inch.

Housing 32 is made from the same material as flexible bag 12 tofacilitate heat sealing housing 32 to flexible bag 12 by, for example,ultrasonic welding. Diaphragm 34 is made from chlorofluro-silicon havinga thickness, t, of about 0.010 inch. Diaphragm 34 can also be made fromother suitable materials which have a memory which causes portions 56,58 of diaphragm 34 to spring back, after inflation, and abut againstsurface 56 to form a seal. The Shore A durometer of the diaphragm rangesbetween 30 and 60 so that the diaphragm is soft enough to ensure propersealing between diaphragm 34 and surface 56. A coat of oil, for examplesilicon, is typically applied to the surface of diaphragm 34 which isadjacent to surface 56 to enhance the sealing capabilities of thediaphragm. Retainer post 36 is typically made from Delrin™ or othersuitable materials, including PVC and high density polyethylene toprovide a desired stiffness to retainer post 36.

In use, as shown in FIG. 2D, rim 62 of housing 32 engages with a wall 64of a container 66 (FIG. 3) in an opening 63. Opening 63 is smaller indiameter than that of rim 62. Tapered surface 68 of rim 62 facilitatesinsertion of rigid valve assembly 16 into opening 63. In addition,tapered surface 68 helps form a seal with a fill nozzle 121 (FIG. 4B)during inflation of bag 12. Shoulder 70 of housing 32 abuts against aninner surface 74 of wall 64 to prevent rigid housing 32 from beingpushed through wall 64 when rigid housing 32 is inserted into the wall.Contact of shoulder 70 of housing 32 with surface 74 of wall 64 providestactile feedback to an operator that rigid valve assembly 16 is fully inplace when snapped into the wall of the container. When rigid valveassembly 16 is mounted in opening 63, entrance opening 40 is flush withor recessed from an outer surface 75 of wall 64. In other words,entrance opening 40 does not protrude outwardly beyond outer surface 75.Rigid valve assembly 16 is used with containers having wall thicknesseswhich range from about 0.0625 inch to about 0.3 inch. Opening 63typically has a diameter of about 0.375 inch.

Referring to FIG. 3, dunnage bag 10 is shown fully inflated in container66 holding several articles 80. Rigid valve assembly 16 is mounted inopening 63 in wall 64 of container 66. Rigid valve assembly 16 islocated close to edge 28 (FIG. 1) of flexible bag 12 to allow pleat 26(FIG. 1) to fully unfold to maximize the volume expansion of the bag sothat the bag conforms about articles 80 carried within the container.Further, pleat 26 relieves the strain on flexible bag 12 near the regionaround rigid valve assembly 16. Dunnage bag 10 fills void regions withincontainer 66 and wedges between articles 80 and the walls of container66 to prevent these articles from moving within container 66 duringshipment. Dunnage bag 10 is typically two to three inches larger in bothwidth and length than that of container 66 to ensure that dunnage bag 10properly fills the void regions about articles 80.

The following is a description of a system which automatically inflatesthe dunnage bag, and seals the container which holds the bag andarticles for shipment. Referring to FIG. 4A, a packaging system 90includes a pair of conveyors 92, 94 of a conveying system, and ataper/inflater station 97. Conveyor 92 transports container 66 in thedirection of arrow 93 to station 97 after an operator mounts rigid valveassembly 16 in an opening of a wall of container 66, as shown in FIG.2D. Next the operator folds a pair of minor flaps 107 and then a pair ofmajor flaps 108 inward to a closed position. In station 97, a taper 96seals the container and an inflating system 98 inflates dunnage bag 10.Conveyor 94 transports the packaged containers in the direction of arrow95 away from station 97. A pair of belt drivers 100, 101 on either sideof container 66 pulls the container through station 97. Each of beltdrivers 100, 101 extend vertically from a base 102 of station 97, andare guided along a respective pair of slots 106. Belt drivers 100, 101pneumatically push against a pair of vertical walls 104 (of which onlyone is shown) of container 66, thereby urging the walls inward tominimize a gap 117 at a top 118 of container 66 which is formed betweenmajor flaps 108 when the flaps are in a folded, closed position.

Taper 96 is supported on a cross bar 110 which is held by a pair ofcolumns 111, 112 of station 97. Taper 96 includes a roll of tape 114 anda tape applying device 116. A sensor (not shown) detects the arrival andheight of container 66, whereupon tape applying device 116 ispneumatically pushed by a pneumatic controller (not shown) against top118 of container 66 with a predetermined force. As container 66 advancesthrough station 97, tape applying device 116 applies a strip of tapealong gap 117 to seal the container.

Inflating system 98 includes a pneumatically actuated arm 120 held in ahousing 122 which is supported in column 111. Housing 122 is connectedto cross bar 110 within column 111 so that housing 122 moves up and downalong with tape applying device 116. The height of housing 122 and thustape applying device 116 is pneumatically adjusted by the pneumaticcontroller. A fill nozzle 121 is held in arm 120 and is connected to ahose (not shown) which supplies compressed air to the fill nozzle. Fillnozzle 121 includes a pliable closed-cell foam end 126 (FIG. 4B) whichsealably engages with entrance opening 40 of rigid valve assembly 16during inflation of dunnage bag 10. Prior to the arrival of container 66in station 97, arm 120 is urged rearward to a location 124 of housing122. The speed of a motor (not shown) of belt drivers 100, 101 ismonitored so that the precise speed of container 66 through station 97is known. A sensor (not shown) positioned on station 97 determines aleading edge 105 of incoming container 66. The motor speed and theinformation from the sensors is used to determine the precise locationof rigid valve assembly 16 when the valve assembly is mounted in opening63 (FIG. 2D). In other words, the speed at which container 66 advancesthrough station 97 and the location of leading edge 105 are known sothat the precise time at which arm 120 pushes fill nozzle 121 againstrigid valve assembly 16 is known. Thus, a predetermined time afterleading edge 105 of container 66 is detected, arm 120 pushes fill nozzle121 against rigid valve assembly 16 to begin the inflation sequence. Arm120 is mounted on a mechanism which allows arm 120 to move forward inhousing 122 with rigid valve assembly 16 as container 66 moves in thedirection of arrow 130. After dunnage bag 10 is inflated, arm 120 andthus fill nozzle 121 are pulled away from rigid valve assembly 16. Arm120 is then pneumatically urged rearward to location 124 of housing 122.

During inflation, as shown in FIG. 4B, end 126 of fill nozzle 121sealably engages with entrance opening 40 of rigid valve assembly 16.Air flows in the direction of arrows 128 from fill nozzle 121 throughrigid valve assembly 16 into flexible bag 12. The force of the flowingair folds diaphragm 34 around retainer post 36 to create a passageway130 through rigid valve assembly 16. After inflation, diaphragm 34 snapsback against surface 56 of housing 32 because of the spring behavior ofdiaphragm 34 and the internal pressure inside flexible bag 12.

Inflating system 98 is shown in greater detail in FIG. 5. Fill nozzle121 of inflating system 98 is connected to a compressor 132 whichsupplies pressurized air for inflating dunnage bag 10. The pressurizedair from compressor 132 is directed through a manifold 134 to threepressure regulators 136, 138 and 140 which reduce the supply pressure to100 psi, 40 psi, and 6 psi, respectively. Regulators 136, 138 and 140are connected in turn to a second manifold 142 which distributes the airthrough a flow meter 144 to fill nozzle 121. A flow meter 144 monitorsthe flow rate of air to fill nozzle 121. Three solenoids 146, 148, and150 are located in the lines connecting manifold 142 and regulators 136,138, and 140, respectively. Solenoids 146, 148, 150 and flow meter 144are electrically connected to a controller 152, for example, aprogrammable logic controller. Controller 152 through the controlling ofthe operation and sequencing of solenoids 146, 148 and 150 controls theinflation sequence of the bag. A pressure transducer 154 which monitorsthe pressure within dunnage bag 10 is positioned near fill nozzle 121and is electrically connected to controller 152. During inflation ofdunnage bag 10, feedback signals from flow meter 144 and pressuretransducer 154 are transmitted via a pair of control lines 156 and 158,respectively, to controller 152. When a desired pressure is detected,controller 152 terminates the inflation sequence. Typically, for a 0.3ft³ dunnage bag, air at 100 psi is first supplied for about 500 msec ata flow rate of about 600 liters/min, then at 40 psi supplied for about500 msec at about 325 liters/min, and finally at 6 psi supplied forabout 1 sec at a flow rate of about 100 liters/min. Thus, the totalinflation process takes about 2 seconds.

In operation, container 66 is transported by conveyor 92 towards station97. Prior to arrival at station 97, an operator places articles 80inside container 66. Subsequently, an operator places dunnage bag 10inside container 66 and mounts rigid valve assembly 16 in hole 63 ofwall 64 of container 66 (FIG. 3). Alternatively, the operator can firstplace dunnage bag 10 inside container 66, and then place the articles ontop of the bag. The operator then folds minor flaps 107 and major flaps108 to a closed position. The subsequent packaging steps are fullyautomated. Belt drivers 100, 101 receive container 66 and pull thecontainer through station 97. As container 66 advances through station97, tape applying device 116 is activated by the pneumatic controllerand applies a strip of tape along the top of container 66 therebysealing gap 117 between major flaps 108 previously folded by theoperator. A sensor (not shown) detects leading edge 105 of container 66,and then after a predetermined time the pneumatic controller (not shown)actuates arm 120. Arm 120 pushes fill nozzle 121 against rigid valveassembly 16, and the inflation process begins. Fill nozzle 121 moveswith container 66 while dunnage bag 10 is being inflated. The entireinflation process takes about 3 seconds. After dunnage bag 10 isinflated, fill nozzle 121 is pneumatically pulled from rigid valveassembly 16, and arm 120 is pneumatically returned to its initialposition. Packaging system 90 is capable of packaging about 15containers per minute.

In other embodiments of the packaging system, controller 152 can be aCPU running software instead of a programmable logic controller. Each oftaper 96 and inflating system 98 can be a stand alone system. Thus thedunnage bag may be inflated prior to or after the sealing of thecontainer is completed. Solenoids 146, 148, 150 can each be activatedfor a predetermined time. The location of rigid valve assembly 16 whenit is mounted in opening 63 can be determined by a pattern recognitionsystem. In addition to the sensor used to detect the leading edge of thecontainer, there can be an additional sensor to detect the trailing edgeof the container so that the width of the container can be determined.The known width then enables the packaging system to determine the timeat which arm 120 forces fill nozzle 121 against the rigid valve assemblyfor containers of various widths. In other embodiments, the pitch andamplitude of the noise generated by the flow of air through the fillnozzle can be used to monitor the inflation sequence.

In another embodiment of the packaging system, as shown in FIG. 6,housing 122 holds a swell detector 170. Swell detector 170 is typicallya linear transducer which includes a body 172, and a rod 174 that movesin and out of body 172 as indicated by double arrows 176. An enlargedhead 178 is attached to an end of rod 174.

When container 66 arrives in station 94 (FIG. 4A), swell detector 170pushes enlarged head 178 against the wall of container 66. Before thecontainer is inflated, the walls of the container are substantially flatas indicated by the straight lines 180. While the dunnage bag within thecontainer is being inflated, the walls of the container swell outward asindicated by the curved lines 182. The deflection of the wall on whichenlarged head 178 abuts against causes enlarged head 178 to move adistance d. This distance is correlated with the pressure within thebag. When a desired pressure is detected, the inflation sequence isterminated. If the distance d decreases after the completion of theinflation sequence, then it is likely that the dunnage bag has a leak.In other words, the operator can monitor the distance d after theinflation sequence and determine if there is a leak in the bag.

Other embodiments of the dunnage bag differ slightly from the embodimentdescribed above. For example, another embodiment shown in FIG. 7A as adunnage bag 210 includes a flexible valve assembly 216 partiallyinserted into a flexible bag 212 near a center portion 213 of flexiblebag 212. Flexible valve assembly 216 includes a rigid collar 232 formounting in an opening in a wall of a container similar to the devicediscussed with reference to FIG. 2D. Rigid collar 232 defines an opening240 into the flexible valve for inflating flexible bag 212. Flexiblevalve assembly 232 enables flexible bag 212 to conform to the voidregions in container 66 carrying articles 80 for shipment withoutstraining the region near center portion 213 when flexible bag 212 isinflated. Flexible bag 212 may include a pleat similar to that describedwith reference to FIG. 1.

Flexible valve assembly 216 is shown in greater detail in FIG. 7B.Flexible valve assembly 216 includes two opposed sheets 218 and 220sealed along three edges 222, 224 and 226. Alternatively, flexible valveassembly 216 can be made from a single sheet and folded along one edge,for example edge 222, and sealed along the other two edges 224 and 226.Flexible valve assembly 216 has an open end 228 so that a passageway isdefined from opening 240 of rigid collar 232 to the inside of flexiblebag 212. Flexible valve 216 is bonded to flexible bag 212 near centerportion 213 of the bag so that an inner portion 242 of flexible bag 212resides inside the bag. When dunnage bag 210 is inflated, sides 218 and220 of portion 242 are urged together by the internal pressure of thedunnage bag thereby creating a seal and preventing air from escaping.

Yet another embodiment shown in FIG. 7C as a dunnage bag 310 includes aflexible valve assembly 316 partially inserted into a flexible bag 312at an attachment region 313. Flexible valve assembly 316 also includes arigid collar 332 which provides an opening into the flexible valveassembly. The construction and operation of flexible valve assembly 316is similar in most respects to flexible valve assembly 216 describedwith reference to FIGS. 7A and 7B except for the location of theattachment region of the valve assembly to the flexible bag. Attachmentregion 313 is located on an edge 314 of flexible bag 312. Sinceattachment region 313 is typically near the location at which rigidcollar 332 is mounted in an opening of a wall of a container, the amountof material required to form rigid valve assembly 316 is minimized.

In another embodiment, shown in FIG. 8, a dunnage bag 360 includes aflexible valve assembly 362 partially inserted in a flexible bag 364.Flexible valve assembly 362 does not have a rigid collar, but thesealing of flexible valve assembly 362 is similar to that of the valveassembly described with reference to FIGS. 7A-7B. An outer portion 365of flexible valve assembly 362 includes two flaps 366, 368. Each offlaps 366, 368 has an adhesive 370 applied to a respective outer surface372, 374. When flaps 366, 368 are spread apart, the flaps define anopening 376.

To mount flexible valve assembly 362 in a wall of a container, theoperator first inserts the valve assembly from the inside of thecontainer through a slit in the wall. Next, the operator spreads flaps366, 368 apart and pushes the flaps against the wall to cause theadhesive to adhere the flaps to the wall. During the inflation sequence,the inflating system supplies pressurized air to opening 376 to inflatedunnage bag 360.

Another embodiment shown in FIG. 9 as a rigid valve assembly 380includes a housing 382, a circular diaphragm 384, and a retainer post386 which secures diaphragm 384 within housing 382. The operation ofrigid valve assembly 380 is similar to valve assembly 16 described withreference to FIGS. 2A-2D. Housing 382 defines a bore 386 with anentrance opening 388. Housing 382 includes an outwardly extending rim393 and an outwardly extending shoulder 394 spaced from rim 393. Aninwardly extending rim 395 of housing 382 includes a tapered surface396.

When rigid valve assembly 380 is mounted in an opening of a wall 390,entrance opening 388 protrudes beyond an outer surface 392 of wall 390.In addition, shoulder 394 abuts against an inner surface 397 of wall390, and rim 393 abuts against outer surface 392 to hold rigid valveassembly 380 in the opening of wall 390.

Still another embodiment shown in FIG. 10 as a dunnage bag 410 includesa rigid valve assembly 416 connected to a flexible bag 412 having twoopposed sides 418 and 420. Sides 418 and 420 are tacked together atseveral points 421 such that flexible bag 412 has a quiltedconstruction. Thus opposed sides 418 and 420 remain substantiallyparallel to each other when flexible bag 412 is inflated. Rigid valveassembly 416 is similar to the valve assembly discussed with referenceto FIGS. 2A-D. Dunnage bag 410, however, can include any one of thevalve assemblies described with reference to FIGS. 7A-9. When dunnagebag 410 is placed at the bottom of a container and inflated, dunnage bag410 acts as level quilted pad upon which an article can rest withoutrolling towards a wall of the container. Another dunnage bag, forexample dunnage bag 10 (FIG. 1), can then be placed on top of thearticle without an operator having to hold the article in the center ofdunnage bag 410.

In another embodiment shown in FIG. 11, a composite dunnage bag 450includes a rigid valve assembly 451, and has the features of bothdunnage bag 410 (FIG. 10) and dunnage bag 10 (FIG. 1). Dunnage bag 450includes a portion 452 joined by a mid portion 454 to another portion456. Portion 452 has a substantially smooth outer surface, and portion456 has a quilted construction similar to the dunnage bag described withreference to FIG. 10. In use, the operator places dunnage bag 450 in thecontainer such that portion 456 rests on the bottom of the container.Next, the operator places an article 458 on top of portion 456 and thenfolds portion 452 over the article. The remaining packaging sequence isidentical to that described above with reference to FIGS. 4A-5.

In yet another embodiment shown in FIG. 12A as a dunnage bag 510includes a flexible bag 512 which has multiple protrusions 526 extendingoutwardly from a surface 528 of flexible bag 512. Dunnage bag 510 alsoincludes a rigid valve assembly 516 similar to rigid valve assembly 16discussed previously with reference to FIGS. 2A-2D. Dunnage bag 510, aswell as dunnage bag 450 (FIG. 11) can be used with any one of the valveassemblies described with reference to FIGS. 7A-9.

Dunnage bag 510 in use is shown in FIG. 12B where rigid valve assembly516 of dunnage bag 510 is mounted in an opening 563 of container 566which carries articles 580. When flexible bag 512 is inflated,protrusions 526 effectively grab article 580 by expanding into the spaceabout article 580. Protrusions 526 prevent article 580 from shiftingwhen side loads are applied to container 566 in the direction of arrows590.

In other embodiments, any one of the flexible bags described above maybe adhered to the interior of the container, for example, with anadhesive. Thus the combination of the flexible bag and container wouldform a single integrated dunnage bag.

Other embodiments are within the scope of the following claims.

What is claimed is:
 1. An inflating system comprising: a fill nozzlewhich during use engages with an entrance end of a valve assembly of aninflatable bag within a container and supplies pressurized gas to thevalve assembly to inflate the bag; and a swell monitor assembly whichmonitors deflection of a wall of the container during inflation of thebag within the container.
 2. The inflating system of claim 1 wherein theswell monitor assembly comprises a linear transducer.
 3. The inflatingsystem of claim 1 further comprising a mechanical arm which supports thefill nozzle and which during use pushes the fill nozzle into engagementwith the entrance end of the valve assembly.
 4. The inflating system ofclaim 3 wherein the mechanical arm is a pneumatically actuated arm. 5.The inflating system of claim 3 further comprising a conveyor system onwhich both the mechanical arm and the swell monitor are mounted.
 6. Theinflating system of claim 1 wherein the swell detector assembly is alsoadapted to monitor deflation of the bag in the container by monitoringan inward deflection of the wall after inflation of the bag has stopped.7. An inflation system comprising: a fill nozzle which during usesupplies pressurized air to an inflatable bag within a container so asto inflate the bag; and a swell monitor assembly which monitorsdeflection of a wall of the container during inflation of the bag withinthe container.
 8. The inflation system of claim 7 further comprising aconveyor system on which both the fill nozzle and the swell monitor aremounted.
 9. The inflation system of claim 8 further comprising a tapersystem mounted on the conveyor system.
 10. The inflating system of claim7 wherein the swell monitor assembly comprises a linear transducer. 11.The inflation system of claim 7 wherein the swell detector assembly isalso adapted to monitor deflation of the bag in the container bymonitoring an inward deflection of the wall after inflation of the baghas stopped.
 12. An inflating system comprising: a fill nozzle whichduring use engages with an entrance end of a valve assembly of aninflatable bag within a container and supplies pressurized gas to thevalve assembly to inflate the bag; a mechanical arm which supports thefill nozzle and which during use pushes the fill nozzle into engagementwith the entrance end of the valve assembly; a swell detector assemblywhich detects deflection of a wall of the container during inflation ofthe bag within the container; and a conveyor system on which both themechanical arm and the swell detector are mounted.
 13. The inflatingsystem of claim 12 wherein the swell detector assembly comprises alinear transducer.
 14. The inflating system of claim 12 wherein themechanical arm is a pneumatically actuated arm.
 15. An inflation systemcomprising: a fill nozzle which during use supplies pressurized air toan inflatable bag within a container so as to inflate the bag; a swelldetector assembly which detects deflection of a wall of the containerduring inflation of the bag within the container; and a conveyor systemon which both the fill nozzle and the swell detector are mounted. 16.The inflation system of claim 15 further comprising a taper systemmounted on the conveyor system.
 17. The inflating system of claim 15wherein the swell detector assembly comprises a linear transducer.